A method for manufacturing parts or devices using additive manufacturing is provided. The method forms the parts or devices, and also forms a transition layer or transition layers of partially or incompletely sintered powder between a build-plate and/or supports provided on the build-plate, and/or a gap or gaps of unsintered powder, or partially or incompletely sintered powder between the supports and the parts. The transition layer(s) and the gap(s) facilitate separation of the parts or devices from the build-plate or the supports provided on the build-plate.

The system and method for an additively manufactured self-destructive delay device is a bellow/lattice structure or other form. The device may be installed as a replacement to a previous device, where the device yields under the deployment force at a specific rate to match the time-displacement curve established by a previous hydraulic delay device. The delay device has a virtually unlimited lifespan, is cheap to manufacture, and can be adaptable to other loads and conditions for use in or on other platforms. This solution can be applied anywhere where mechanical delay devices are needed within systems. Some examples include wing/fin deployment mechanisms, safety crumple zones, or devices that act as shear pins.

An apparatus comprises a controller to cause an additive manufacturing system to perform a method, the method comprising: controlling the additive manufacturing system to provide a plurality of articles in a multi-layer build arrangement in a build chamber, the multi-layer build arrangement comprising a plurality of article layers, each article layer comprising an article; ejecting a portion of the multi-layer build arrangement from the build chamber; and determining when a divider can be used to divide a first volume of build material of the multi-layer build arrangement from a remaining volume of build material of the multi-layer build arrangement, wherein the first volume comprises an article layer.

In an example of a method for three-dimensional (3D) printing, build material layers are patterned to form an intermediate structure. During patterning, a binding agent is selectively applied to define: a build material support structure and a patterned intermediate part. Also during patterning, i) the binding agent and a separate agent including a gas precursor or ii) a combined agent including a binder and the gas precursor are selectively applied to define a patterned breakable connection between at least a portion of the build material support structure and at least a portion patterned intermediate part. The intermediate structure is heated to a temperature that activates the gas precursor to create gas pockets in the patterned breakable connection.

In an example of a method for three-dimensional (3D) printing, build material layers are patterned to form an intermediate structure. During patterning, a binding agent is selectively applied to define: a build material support structure and a patterned intermediate part. Also during patterning, i) the binding agent and a separate agent including a gas precursor or ii) a combined agent including a binder and the gas precursor are selectively applied to define a patterned breakable connection between at least a portion of the build material support structure and at least a portion patterned intermediate part. The intermediate structure is heated to a temperature that activates the gas precursor to create gas pockets in the patterned breakable connection.

A mask is provided for an additively manufactured part including a plurality of spaced openings in a surface of the part. The mask is made with the part and includes an attachment ligament configured to integrally couple to the part between the openings in a cantilever fashion. First and second cover members include a proximal ends integrally coupled to the attachment ligament and distal ends extending at least partially over a respective portions of the plurality of openings. A detachment member extends from each of the first and second cover members. The attachment ligament is the sole connection to the part. The mask may have an umbrella shape in cross-section.

A mask is provided for an additively manufactured part including a plurality of openings in a surface of the part. The mask is made with the part and includes an attachment ligament configured to integrally couple to the part adjacent the plurality of openings. A cover member include a proximal end integrally coupled to the attachment ligament and distal end extending at least partially over the plurality of openings. A detachment member may optionally extend from adjacent the cover member. The attachment ligament is the sole connection to the part. The mask may have an L-shape in cross-section.

A protective mask for a part, the part including a plurality of openings in a surface thereof, is provided. The protective mask includes a mounting member at least partially within each of at least two of the plurality of openings. Each mounting member includes a water soluble material. A masking member couples the at least two mounting members. The masking member includes a non-water soluble material. Each mounting member includes a first plurality of integral layers of the water soluble material, and the masking member includes a second plurality of integral layers of the non-water soluble material. The protective mask can be made by a two material additive manufacturing system. A related method is also provided.

An orthodontic retainer is configured for application to a lingual surface of a patient's teeth. The retainer is custom designed to exactly match the shape of the lingual side of the patient's teeth and is formed from a plurality of tooth-adhering portions connected by elongated connection portions. The tooth-adhering portions each have a generally flat top edge and a generally curved bottom edge. The connection portions are located at a position below the top edge and above the bottom edge of the tooth-adhering portions. The retainer is formed as a single piece by milling, injection molding or 3D printing.

Method for additive manufacturing of at least one component comprises the manufacture, by depositing and selective melting of layers of powder, of at least one intermediate assembly comprising the component produced at an inclined angle and forming an angle of between 20° and 70° with a manufacturing support plate, a support interposed between the support plate and a lower base of the component, and at least one local supporting element resting against the rear frontal face of the component. During the selective-melting phases of the manufacturing step, incipient cracks are formed in regions of connection of the support and of the supporting element to the component. The component is separated from the support and the local supporting element after the manufacturing step by breaking of the connecting regions.